Automated storage and retrieval system

ABSTRACT

An autonomous rover including a frame having a first end and a second end longitudinally spaced from the first end and forming a payload bay, the payload bay being sized to support a pickface, a common active registration surface configured to engage the pickface, and a drive section connected to the common active registration surface, the drive section being configured to variably position the common active registration surface relative to at least one storage shelf of an automated storage and retrieval system to effect placement of the pickface on the storage shelf so that pickfaces are substantially continuously arranged along the at least one storage shelf with a predetermined storage spacing between the pickfaces.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/798,216, filed Oct. 30, 2017 (now U.S. Pat. No. 9,988,213 issued Jun.5, 2018), which is a continuation of U.S. patent application Ser. No.14/215,310 filed on Mar. 17, 2014 (now U.S. Pat. No. 9,802,761) which isa non-provisional of and claims the benefit of and priority from U.S.Provisional Patent Application No. 61/790,801, filed Mar. 15, 2013, thedisclosures of which are incorporated by reference herein in theirentireties.

BACKGROUND 1. Field

The exemplary embodiments generally relate to material handling systemsand, more particularly, to transport and storage of items within thematerial handling systems.

2. Brief Description of Related Developments

Generally the storage of items within, for example, a warehouse requiresa large building or storage structure space with an associatedfootprint. Automated vehicles or robots may be used in these warehousesto place items in storage and remove items from storage.

It would be advantageous to have an automated vehicle that canefficiently pick items for removal from the storage structure. It wouldalso be advantageous to have an automated vehicle that can accessmultiple storage levels so that a storage density of the storagestructure may be increased.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodimentsare explained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 is a schematic illustration of an automated storage and retrievalsystem in accordance with aspects of the disclosed embodiment;

FIG. 2 is a schematic illustration of an autonomous rover in accordancewith aspects of the disclosed embodiment;

FIGS. 3A and 3B are schematic illustrations of a portion of the storageand retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 4 is a schematic illustration of a portion of the autonomous roverof FIG. 2 in accordance with aspects of the disclosed embodiment;

FIG. 5 is a schematic illustration of a portion of the autonomous roverof FIG. 2 in accordance with aspects of the disclosed embodiment;

FIGS. 6A-6D are schematic illustrations of payload registration inaccordance with aspects of the disclosed embodiment;

FIGS. 7A-7C are schematic illustrations of the autonomous rover of FIG.2 in accordance with aspects of the disclosed embodiment;

FIG. 8 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIG. 9 is a schematic illustration of an autonomous rover in accordancewith aspects of the disclosed embodiment;

FIGS. 9A-9D are schematic illustrations of a portion of the automatedstorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIGS. 10A-10C and 11 are schematic illustrations of portions of thestorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIGS. 12-15 are schematic illustrations of a portion of the automatedstorage and retrieval system is shown in accordance with aspects of thedisclosed embodiment;

FIG. 16 is a flow diagram in accordance with aspects of the disclosedembodiment; and

FIG. 17 is a flow diagram in accordance with aspects of the disclosedembodiment.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates a storage and retrieval system inaccordance with an aspect of the disclosed embodiment. Although theaspects of the disclosed embodiment will be described with reference tothe drawings, it should be understood that the aspects of the disclosedembodiment can be embodied in many alternate forms. In addition, anysuitable size, shape or type of elements or materials could be used.

In accordance with aspects of the disclosed embodiment the storage andretrieval system 100 may operate in a retail distribution center orwarehouse to, for example, fulfill orders received from retail storesfor case units such as those described in U.S. patent application Ser.No. 13/326,674 filed on Dec. 15, 2011, the disclosure of which isincorporated by reference herein in its entirety.

The storage and retrieval system 100 may include in-feed and out-feedtransfer stations 170, 160, input and output vertical lifts 150A, 150B(generally referred to as lifts 150), a storage structure 130, and anumber of autonomous rovers 110. The storage structure 130 may includemultiple levels of storage rack modules where each level includesrespective storage or picking aisles 130A, and transfer decks 130B fortransferring case units (e.g. provided on a respective level) (FIG. 16,Block 1600) between any of the storage areas of the storage structure130 and any shelf of the lifts 150. The storage aisles 130A, andtransfer decks 130B are also configured to allow the rovers 110,provided on a respective level (FIG. 16, Block 1601), to traverse thestorage aisles 130A and transfer decks 130B for placing case units intopicking stock and to retrieve ordered case units.

The rovers 110 may be any suitable autonomous vehicles capable ofcarrying and transferring case units throughout the storage andretrieval system 100. Suitable examples of rovers can be found in, forexemplary purposes only, U.S. patent application Ser. No. 13/326,674filed on Dec. 15, 2011; U.S. patent application Ser. No. 12/757,312filed on Apr. 9, 2010; U.S. patent application Ser. No. 13/326,423 filedon Dec. 15, 2011; U.S. patent application Ser. No. 13/326,447 filed onDec. 15, 2011; U.S. patent application Ser. No. 13/326,505 Dec. 15,2011; U.S. patent application Ser. No. 13/327,040 filed on Dec. 15,2011; U.S. patent application Ser. No. 13/326,952 filed on Dec. 15,2011; and U.S. patent application Ser. No. 13/326,993 filed on Dec. 15,2011, the disclosures of which are incorporated by reference herein intheir entireties. The rovers 110 may be configured to place case units,such as the above described retail merchandise, into picking stock inthe one or more levels of the storage structure 130 and then selectivelyretrieve ordered case units for shipping the ordered case units to, forexample, a store or other suitable location.

The rovers 110 and other suitable features of the storage and retrievalsystem 100 may be controlled by, for example, one or more central systemcontrol computers (e.g. control server) 120 through, for example, anysuitable network 180. The network 180 may be a wired network, a wirelessnetwork or a combination of wireless and wired networks using anysuitable type and/or number of communication protocols. In one aspect,the control server 120 may include a collection of substantiallyconcurrently running programs that are configured to manage the storageand retrieval system 100 including, for exemplary purposes only,controlling, scheduling, and monitoring the activities of all activesystem components, managing inventory and pickfaces, and interfacingwith the warehouse management system 2500.

Referring now to FIG. 2 the rover 110 may include a frame 110F having afirst end 110E1 and a second end 110E2 longitudinally spaced from thefirst end 110E1. The frame 110F forms a payload bay 200 configured tosupport a pickface within the payload bay 200 in any suitable manner. Inone aspect laterally arranged rollers 200R may support the pickface andallow the pickface to move in the longitudinal direction within thepayload bay. It is noted that a “pickface” as used herein may be one ormore merchandise case units placed one behind the other, side by side,or a combination thereof.

The rover 110 may include one or more active registration members 202,203 such as movable blades or fences having surface(s) that engagepickface edges or side surfaces 210E and provide positive longitudinalregistration of the pickface as a unit with respect to rover frameand/or a global reference frame of the automated storage and retrievalsystem. Positive pickface registration through engagement and movementof pickface side surfaces 210E by a common active registration surfaceof the one or more registration members 202, 203 resolves positionvariance that may be possible with friction registration, and achievesreliable pickface positioning/placement decoupling thepositioning/placement of the pickface from (e.g. relative to) the roverframe 110F. The one or more registration members may also enableconsistent continuous rack storage utility.

The registration members 202, 203 may be disposed at least partly withinthe payload bay 200 for positioning the pickface at a predeterminedposition relative to one or more of the frame 110F or a storage shelf300 (FIG. 3A) of the a storage rack module. In one aspect theregistration member 202, 203 may be common to the case unit(s) formingthe pickface. The registration members 202, 203 may be pusher plates orblades that engage sides of the pickface 210 for positioning thepickface. The registration members 202, 203 may also be active in thesense that at least one of the registration members 202, 203 may belongitudinally movable within the payload bay. For example, as can beseen in FIG. 2, registration member 202 may be fixed relative to theframe while registration member 203 is movable relative to the frame110F in the longitudinal direction. In other aspects both of theregistration members 202, 203 may be movable relative to the frame 110Fin the longitudinal direction.

Any suitable drive section 220, which will be described below, may beconnected to the frame for driving one or more of the registrationmembers 202, 203 in any suitable manner such as that described below.The rover 110 may include any suitable controller 110C that is connectedto the drive section for controlling movement of at least one of theregistration members 202, 203. In one aspect, where one registrationmember 202 is fixed and the other registration member 203 is movable,the controller may control the movable registration member 203 so thatit snugs the pickface against the fixed registration member 202. Thecontroller may know a width of the pickface (which may be determined inany suitable manner such as a look up table, sensors, a longitudinalposition of the movable registration blade within the payload bay, etc.)so that the boundaries of the pickface in at least the longitudinaldirection are known and the position of the pickface can be determinedbased on the location of the fixed registration member 202. In otheraspects, where both registration members 202, 203 are movable thecontroller 110C may control the movement of the registration members202, 203 so that an average position of the registration members 202,203 (e.g. the mid-line ML of the space between the registration members202, 203) substantially matches (e.g. lies along the same line) thelocation (e.g. the centerline CL of the pickface 210 with respect to thelongitudinal direction of the rover) where the pickface 210 is to belocated within the payload bed 200. Snugging the pickface (e.g. holdingthe pickface with the registration members 202, 203 and/or pressing oneor more case unit(s) 210P1, 210P2 of the pickface 210 together foralignment) may also be controlled by the controller 110C using anysuitable force feedback to control a magnitude of the snugging force.The controller 110C may monitor current from one or more motors of thedrive section and use the current alone or with, for example, a Kalmanfilter (or other force estimation algorithm or sensor) to control thesnugging force.

Still referring to FIG. 2 and also to FIGS. 3A and 3B, the rover mayinclude any suitable end effector movably connected to the frame 110Ffor transferring the pickface 210 to and from the payload bay 200. Inone aspect the end effector includes movable fingers 201A, 201B, 201C(generally referred to as fingers 201) that may lift and transport thepickface 210 to and from the payload bay 200. The controller 110C mayposition the registration members 202, 203 so that an edge or sidesurface of the pickface 210E is positioned a predetermined distance X1,X2 from a finger, such as finger 201A or any other suitable referencedatum of the payload bay 200, frame 110F or global reference frame ofthe automated storage and retrieval system. This may be referred to asthe case offset. The case offset may range from substantially zero toany suitable predetermined distance X1 so as to provide any suitablespacing between pickfaces on the support surfaces 300S of storageshelves 300. The positioning of the case unit or pickface with theregistration members 202, 203 allows for a minimized spacing or gap SPbetween adjacent case units or pickfaces. In one aspect registration ofthe case unit or pickface with the registration members 202, 203 mayallow placement of the case unit or pickface on the storage shelf 300 inpredetermined position relative to a feature of the storage shelf 300.For example, the support surface 300S of storage shelf 300 may be formedfrom discontinuous support surfaces 300SS where each portion of thesupport surface 300S is supported by upright members 300U that aresubstantially channel shaped to allow the fingers 201 to be insertedbetween the upright members 300U where the fingers travel verticallybetween the discontinuous support surfaces 300SS. In one aspect theregistration of the case units or pickface may be with respect to atleast a global reference frame of the automated storage and retrievalsystem for placing an edge 210E the case unit or pickface at apredetermine distance from a discontinuous support surface 300SS so thata predetermined spacing SP exits between adjacent case units orpickfaces. The spacing SP may be any suitable spacing and in one aspectis less than a distance X3 between the discontinuous support surface300SS. In one aspect the spacing SP may be a minimized spacing thatprovides only sufficient clearance between adjacent case units orpickfaces to allow contactless insertion or removal of the case units orpickfaces to and from the allocated storage space.

Referring now to FIG. 4 a portion of the rover 110 is illustrated inaccordance with aspects of the disclosed embodiment. As can be seen inFIG. 4 each registration member 202, 203 is movably mounted to a linearguide member 401 in any suitable manner. For example, a sliding coupler403A, 403B (e.g. one coupler for each registration member 202, 203) maybe movably mounted to the linear guide member 401. The sliding coupler403A, 403B may be coupled to a respective registration member 202, 203so that the registration member 202, 203 is supported on a single sideof the registration member 202, 203 (e.g. cantilevered from the linearguide member 401) to allow longitudinal movement of the registrationmembers above the rollers 200R (or other pickface support) and thefingers 201. The linear guide member 401 may be mounted below thepayload bed pickface support surface (e.g. such as rollers 200R).

The drive section 220A may be a two degree of freedom drive section. Inother aspects the drive section may have more or less than two degreesof freedom. As can be seen in FIG. 4 the drive section includes a commondrive member 402 that is fixed at one end 402E1 to the frame 110F andfixed at the other end 402E2 to an opposite end of the frame 110F sothat the common drive member is movably fixed relative to the frame110F. The common drive member may be any suitable member such as, forexample, a band, belt, wire, etc. A motor 400M1, 400M2 may be mounted toa respective registration member 202, 203 in any suitable manner. Eachmotor may include a drive pulley P1 and each sliding coupler may includean idler pulley P2 to form a pulley pair. The common drive member 402may serpentine around the drive pulley P1 and idler pulley P2 of eachpulley pair and be tensioned in any suitable manner so that engagementbetween the drive pulley P1 and the common drive member 402 causeslongitudinal movement of a respective registration member 202, 203 whena corresponding motor 400M1, 400M2 is actuated. As may be realized, themotors 400M1, 400M2 may be any suitable motors such as, for example, astepper motor. The controller 110C may control each motor to generaterelative motion between the registration members 202, 203 and the frame110F for snugging and positioning the pickface using an open controlloop (e.g. through motor commands) or a closed control loop (usingposition data from one or more sensors). As may be realized, anysuitable sensors may be disposed on the frame 110F for obtaining aposition of one or more of the registration members 202, 203 relativeto, for example, the frame. In one aspect an encoder may be placed alongthe linear guide member 401 or on the idler pulleys P2 to provideposition data to the controller.

Referring to FIG. 4B, another two degree of freedom drive section isshown in accordance with another aspect of the disclosed embodiment. Theoperation of the drive section shown in FIG. 4B may be substantiallysimilar to that described above however; the motors 400M1, 400M2 may bemounted to the frame 110F in any suitable manner. In this aspect, eachmotor may drive a corresponding closed loop drive member 402A, 402B(such as e.g. a belt, band, wire, etc.). For example, each motor mayinclude a drive pulley P1 mounted to the output of the motor. Acorresponding idler pulley P2 may be mounted on a longitudinallyopposite side of the frame 110F. The closed loop drive member 402A, 402Bmay be wrapped around or otherwise engaged with its respective drivepulley P1 and idler pulley P2. Sliding coupler 403A may be coupled toclosed loop drive member 402A and sliding coupler 403B may be coupled toclosed loop drive member 402B so that as a respective motor 400M1, 400M2is actuated the closed loop drive member 402A rotates around the pulleysP1, P2 for moving a respective sliding coupler 403A, 403B (and therespective registration member 202, 203).

Referring to FIGS. 6A-6D the registration of a pickface on the rover 110will be described. The fingers 201 may extend to a storage shelf 300(FIG. 3A) and pick one or more case units 210P1, 210P2 from the same ordifferent storage locations (e.g. of the same or different shelves forbuilding a pickface as will be described below) for transfer of the caseunits 210P1, 210P2 into the payload bay 200 (FIG. 2). The fingers 201may lower below the pickface support surface of the payload bay 200 sothat the case units 21P1, 210P2 are placed on, for example, rollers200R. The rover controller 110C may actuate the motors 400M1, 400M2(FIGS. 4 and 5) for moving registration member 203 in the direction ofarrow A1 and for moving registration member 202 in the direction ofarrow A2 until the registration members contact sides of the case units210P1, 210P2 (FIG. 6B). A snugging force, as described above, may beapplied to the case units 210P1, 210P2 by the registration members 202,203 to longitudinally align the case units 210P1, 210P2 (FIG. 6C). Asmay be realized the case units 210P1, 210P2 may also be snugged in thelateral direction using for example, a movable snugging member 110PB anda fixed fence 110FE as described in, for exemplary purposes only, U.S.patent application Ser. No. 12/757,312 filed on Apr. 9, 2010 thedisclosure of which is incorporated herein by reference in its entirety.For example, the movable snugging member 110PB may be movably mounted tothe frame for movement in the direction of arrow A3 so that the movablesnugging member 110PB moves towards and away from the fence 110FE topush the case units 210P1, 210P2 against each other and/or against thefence 110FE. The fence 110FE may be fixed to the frame 110F and providea reference datum for pickface face positioning in the direction ofarrow A3 (e.g. along the longitudinal axis of the rover/the direction ofextension of the rover end effector). The snugged case units 210P1,210P2 which form the pickface 210 may be longitudinally moved as a unit(FIG. 6D), e.g. in the direction of one or more of arrows A1, A2, forpositioning the pickface at a predetermined longitudinal positionrelative to one or more of the payload bay 200, the frame 110F or aglobal reference frame that may define a storage position on the storageshelf 300 as defined storage space location of a storage shelf 300(FIGS. 3A and 3B).

As described above, the rovers 110 may be configured to build pickfaces210 including one or more case units in any suitable manner. In oneaspect, the rovers are capable of picking one or more case units at oneor more locations from storage shelves 300 and positioning the caseunits relative to, for example, the rover frame 110F or any othersuitable reference frame, such as a global reference frame of thestorage and retrieval system, for forming the pickface 210. The pickface210 may be formed adjacent the storage shelf 300 from which the one ormore case units were picked. As may be realized the picking of caseunits from the storage shelves is exemplary and in other aspects therover may also be capable of positioning case units, picked from anysuitable location or locations of an automated storage and retrievalsystem (such as, e.g., the lifts 150A, 150B) for placement of the caseunits as a unit (i.e. pickface) at any suitable predetermined locationwithin the automated storage and retrieval system.

In one aspect, the pickface 210 may be formed adjacent or at the storagelocation (e.g. adjacent or at the storage shelf or other suitablestorage location) upon picking of the case units from one or morestorage locations of the storage shelves 300 (or any other suitablestructure of the automated storage and retrieval system capable ofholding case units). For example, the cases units included in thepickface 210 may be obtained from one location of the storage shelves300 while in other aspects a case unit may be picked from a firststorage location (FIG. 16, Block 1602), a second case unit may be pickedfrom a second location (FIG. 16, Block 1603), and so on until all thedesired case units are placed in the payload bay, to form the pickface210 (FIG. 16, Block 1604). In other aspects, the pickface 210 may alsobe formed as each case unit is picked from one or more inbound shelvesof one or more lifts 150A so that the formed pickface 210 may be placedin a storage location or, in other aspects, on an outbound shelf of alift 150B.

The pickface 210 may include any suitable number of case units arrangedin any suitable configuration as shown in FIGS. 2 and 7A-7C. Forexample, the case units 210Pa, 210P2 may be arranged laterally side byside as shown in FIG. 2 to form pickface 210, longitudinally side byside as shown in FIG. 7C to form pickface 210A or in any othercombination as shown in FIGS. 7A and 7B to form pickfaces 210A, 210C aslong as the combination of case units forming the pickface 210, 210A,210B, 210C allow the pickface 210, 210A, 210B, 210C to havesubstantially straight or otherwise substantially flat sides (e.g. thedimensions of each case unit forming the pickface are substantiallycomplimentary to the other case units forming the pickface) so that thesnugging member 110PB, fence and/or registration members 202, 203 canlongitudinally and/or laterally justify the case units to form thepickface.

Referring to FIG. 8 a portion of the storage and retrieval system inaccordance with aspects of the disclosed embodiment is shown. In thisaspect the storage shelves 800, 800A are substantially flat shelveshaving a substantially flat pickface support surface 800S (e.g. comparedto shelf 300 in which the fingers 201 of the rover extend betweenuprights of the pickface support 300S). The substantially flat pickfacesupport surface 800S may be configured for snag proof storage ofpickfaces (e.g. shrink wrap or the case units themselves may not getcaught on the shelves) and to allow fluids to pass through the shelves.As may be realized any suitable drip tray DT may be placed under theshelf 800 (and shelf 300) to collect fluids that pass through the shelfand to substantially prevent the fluids from contacting case units orpickfaces disposed on other storage levels beneath the shelf 800 (andshelf 300). The storage shelves In this aspect, the rover 110A may besubstantially similar to rover 110 described above however, here therover 110A includes a bladed end effector 810 that includes blades 811,812 that are configured to grip opposing sides of the pickface and totransfer the pickface to and from the payload bed 200. As will bedescribed in greater detail below.

Referring to FIGS. 10A, 10B, 10C and 11 the storage shelves 800 mayallow for a reduction in the number of picking aisles 130A (FIG. 1),reduced rover length which will allow for a reduced transfer deck 130B(FIG. 1) size, and a reduced deck (e.g. both the transfer deck 130B andthe picking aisle deck 130AD) by providing multi-level storage perpicking aisle deck 130AD. The configuration of the shelves 800 may alsoallow for an increase in horizontal and vertical case density whilepositioning/registering the case units or pickfaces with the blades 811,812 may allow for moving the pickface closer together (e.g. reducingpickface spacing as described above). Where the blades are used totransfer the case unit(s) or pickface to and from the storage shelf itis noted that the spacing between the case units allows space for theblades 811, 812 to be inserted between adjacent case units or pickfaces.

In one aspect, the shelves 800 may be constructed of, for example,stamped sheet metal or any other suitable material formed in anysuitable manner. The shelves 800 may include any suitable stiffeningribs/projections 800R faced downward to utilize “dead space” (e.g. spacethat is otherwise not suitable for storage) between the picking aislerails 130R1, 130R2 (that form the picking aisle deck 130AD on which therover travels—while two individual rails 130R1, 130R2 are shown onopposite sides of the picking aisle 130A in other aspects the pickingaisle deck may be a one piece deck member or any other suitablestructure that spans a width of the picking aisle 130A). In otheraspects the shelves may not have stiffening ribs. The stiffening ribs800R may include an opening 10000 on the bottom to allow fluids to passthrough the shelving 800. The openings 10000 of the shelves 800 may beoriented and aligned with a direction (arrow 11002) in which thepickfaces are transferred to and from the shelves 800 and includesmoothed corner transitions with the substantially flat pickface supportsurface 800S. The stiffening ribs 800R may have any suitable shape andsize. In one aspect the shape of the stiffening ribs may allow stackingof the shelves 800 during, for example, transport of the shelves 800 tocustomer locations (FIG. 10C) and/or for storage of the shelves 800 inany suitable location. It is noted that the shelves 800 may be affixedto the storage rack structure 11005 (FIG. 11) and/or the picking aisledeck/rails 130AD, 130R1, 130R2 in any suitable manner. In one aspect theshelves 800 may be removably fixed to the storage rack structure 11005(FIG. 11) and/or the picking aisle deck/rails 130AD, 130R1, 130R2 withremovable fasteners. In other aspects the shelves 800 may not beremovable.

Referring to FIG. 11, in another aspect the shelves 800A may beconstructed of wire (e.g. wire shelves). The wire shelves 800A may haveany suitable configuration such as a wire mesh configuration where theupper members 800AU of the wire shelves 800A are oriented and alignedwith a direction (arrow 11002) in which the pickfaces are transferred toand from the shelves 800A. The wire shelves 800A may be secured to thestorage rack structure 11005 and/or the picking aisle deck/rails 130AD,130R1, 130R2 in any suitable manner. In one aspect the wire shelves 800Amay wrap around the storage rack structure 11005 and/or the pickingaisle deck/rails 130AD, 130R1, 130R2 as shown in FIG. 11 so that thewire shelves 800A are removably fixed to the storage rack structure11005 and/or the picking aisle deck/rails 130AD, 130R1, 130R2substantially without fasteners or other fixing methods (e.g. adhesives,welding, etc.). In other aspects the wire shelves 800A may be removablyfixed to the storage rack structure 11005 and/or the picking aisledeck/rails 130AD, 130R1, 130R2 with any removable fasteners. In otheraspects the shelves 800A may not be removable.

As described above, the storage shelves 800, 800A may be stacked oneabove the other as shown in FIG. 10B. Here there are two storage shelves800V1, 800V2 stacked one above the other and accessible from a singlepicking aisle deck 130AD. In other aspects there may be more than twostacked storage shelves that are accessible from a single picking aisledeck 130AD.

Referring now to FIGS. 9, 9A, 9B, 9C and 9D, as noted above, the rover110A includes a bladed end effector 810 that includes blades 811, 812that may be configured to grip opposing sides of the pickface and totransfer the pickface to and from the payload bed 200A. The blades 811,812 may be connected to a drive section, which may be substantiallysimilar to that described above, for longitudinally moving at least oneof the blades 811, 812 in the direction of arrow 999 (FIG. 9) forgripping the sides of the pickface with electrostatic and/or frictionalforces (FIGS. 8 and 9A-9D). Each of the blades 811, 812 may be atelescopic blade that includes any suitable number of blade members BM1,BM2 where at least one blade member BM1 is slidably coupled to anotherblade member BM2 along an axis of extension of the blade for telescopicextension and retraction of each of the blades 811, 812. Anelectrostatic and/or friction surface 811P, 812P may be fixed to arespective blade member BM1 for engaging the pickface. In other aspectseach blade may be a fixed (e.g. non-telescopic blade) or any othersuitable end effector member. The blade members BM1, BM2 may beconnected to any suitable drive section for driving and extending theblades in the direction of arrow 899 (e.g. along a lateral axis of therover).

The rover 110A may also include active side justification (where oneside blade is fixed and the other is movable or where both blades aremovable in a manner substantially similar to that described above) andsuitable sensors 950 for physical confirmation of case boundaries (FIG.9C). The sensors 950 may be beam line or curtain sensors disposed on theside blades of the bot. The sensors 950 may allow the rover to, onplacing pickfaces, confirm empty and adequate space exists on anysuitable pickface holding location, such as for example a storage shelf800, 800A, for a pickface and to confirm that the pickface is placedwith the correct setback (e.g. the distance the pickface is located froma picking aisle edge of the pickface holding location or any othersuitable reference datum). On picking the sensors 950 may allow for casetargeting and confirmation of the depth to which the blades are extendedinto the storage location. The blades 811, 812 may also provide guidancefor pickfaces being placed in deep storage locations (e.g. at storagelocations that are distant from an edge of, e.g., the storage shelf 800,800A.

The payload bed 200A of the rover 110A may be configured to allowmulti-degree of freedom sliding movement of the pickface 210 (and thecase units forming the pickface) along the surface of the payload bed200A. In one aspect the payload bed may be a substantially flat surfaceconstructed of any suitable material having a low coefficient offriction. In other aspects the payload bed may include a plurality ofball bearings on which the pickface rides. In still other aspects thepayload bed 200A may have any suitable construction that allows for themulti-degree of freedom sliding movement of the pickface 210 (and thecase units forming the pickface) along the surface of the payload bed200A.

Referring to FIGS. 9A-9D transfer of a pickface between a pickfaceholding location, such as for example, storage shelf 800, will bedescribed. The rover 110A enters the picking aisle 130A and stops at apredetermined storage location (FIG. 17, Block 1700). The rovercontroller 110C may operate the end effector drive section tolongitudinally move one or more of the blades 811, 812 to align theblades with the storage location according to, for example, a width ofthe pickface 210 (FIG. 9A). The rover controller 110C may also operatethe drive section to extend the blades 811, 812 into the storagelocation so that the blades straddle the sides of the pickface 210 (FIG.9B) (FIG. 17, Block 1701). The sensor 950 may provide feedback to thecontroller 110C for determining how deep the blades 811, 812 areextended into the storage location and to determine the leading andtrailing edge boundaries (with respect to the direction of extension ofthe blades) of the pickface or a case unit(s) that forms at least partof the pickface (FIG. 9C) (FIG. 17, Block 1702). Once the blades 811,812 are located in a predetermined position relative to the pickface 210the blades may move longitudinally to engage or otherwise grip thepickface 210 (or case unit(s) that form at least part of the pickface)in a manner substantially similar to that described above using, forexample, force feedback (FIG. 17, Block 1703). For removing the pickface210 or case unit(s) that form at least part of the pickface (FIG. 17,Block 1704) from the storage location the support surface of the payloadbed 200A may be positioned substantially at the same height or lowerthan the support surface of the storage shelf 800 so that as the blades811, 812 are retracted the pickface 210 being gripped by the blades 811,812 can slide off of the storage shelf 800 onto the payload bed 200A(FIG. 9D). Here the blades 811, 812 may not lift the pickface 210 butrather the blades 811, 812 may slide the pickface 210 along the surfaceof the storage shelf 800 and/or payload bed 200A. In other aspects, theblades 811, 812 may lift the pickface for transfer between the storagelocation and the payload bed. It is noted that the lowered payload bed200A may expose a stationary fence 210FE that may be substantiallysimilar to fence 110FE such that if a pickface is being built by therover 110A the case units forming the pickface can be laterally andlongitudinally registered within the payload bay of the rover 110Arelative to the frame 110F (FIG. 2) and/or a global reference frame ofthe automated storage and retrieval system in a manner substantiallysimilar to that described above using the blades 811, 812 forlongitudinal registration and the snugging member 110PB and fence 110FEfor lateral registration (FIG. 17, Block 1705). During transport of thepickface 210, the pickface may be held by the blades 811, 812 and/or bythe snugging member 110PB and fence 110FE. To place the pickface 210into any suitable pickface holding location the rover 110 may bepositioned at a predetermined location relative to the pickface holdinglocation. The payload bed 200A may be raised to a level substantiallyequal to or above the support surface of the pickface holding locationand the blades 811, 812 may slide the pickface 210 off of the payloadbed 200A onto the support surface of the pickface holding location (FIG.17, Block 1706) in a manner substantially similar to that describedabove for sliding the pickface onto the payload bed 200A. As may berealized, while transfer of payload to and from the rover 110A isdescribed with respect to pickface 210 it should be understood that theabove-description also applies to transfer of individual case units toand from the rover 110A. In addition, while reference is made to thestorage shelf 800, 800A it should be understood that the rover maytransfer a case unit and/or a pickface formed of case units to anysuitable pickface holding location such as the storage shelves 800,800A, a shelf of a lift 150A, 150B or any other suitable location.

Referring now to FIGS. 12-15 a portion of the automated storage andretrieval system is shown in accordance with aspects of the disclosedembodiment. In this aspect, the rover 110A is configured to accessstacked storage shelves 800V1A, 800V2A, 800V1B, 800V2B from a singlepicking aisle deck 130ADV1, 130ADV2 as noted above with respect to FIG.10B. For exemplary purposes only, in this aspect each picking aisle deck130ADV1, 130ADV2 provides access to levels of storage but in otheraspects each picking aisle ma provide access to more than two levels ofstorage. It is noted that the level of storage accessed by each pickingaisle may vary from one picking aisle deck to another picking aisle deck(e.g. one deck may provide access to a first number of storage levelswhile another deck may provide access to a second number storage levelswhere the second number is different than the first number). The rover110A may include a vertical drive section 13000 (FIG. 13) that may liftor lower the payload bay 200 (e.g. the payload bed 200A, the snuggermember 110PB to a predetermined height corresponding to a storage levelfrom or to which a case unit or pickface is to be picked or placed in amanner substantially similar to that described above with respect toFIGS. 9A-9D. The vertical drive section 13000 may be any suitable drivesection configured to raise and lower the payload bed 200 such as, forexample, a linear actuator, a screw drive, scissor lift, a magneticdrive, etc. In another aspect, where the blades 811, 812 lift the caseunit or pickface off of the payload bed 200A for transfer to storagelocation the vertical drive 13000 may be configured to cause verticalmovement of the blades 811, 812 while the payload bed 200A remainsvertically fixed.

In accordance with one or more aspects of the disclosed embodiment amethod for building a pickface including at least two case units in anautomated storage and retrieval system having an array of storage spacesis provided. The method includes providing an autonomous roverconfigured to transfer case units between the rover and the array ofstorage spaces; picking, with the rover, a first case unit from apredetermined storage space; and picking, with the rover, at least asecond case unit from a different predetermined storage space; whereinthe first case unit and the at least second case unit form the pickfaceand are transported as a unit.

In accordance with one or more aspects of the disclosed embodiment thepredetermined storage space and the different predetermined storagespace are disposed on shelves that are stacked one above the other.

In accordance with one or more aspects of the disclosed embodiment anautonomous rover is provided. The autonomous rover includes a framehaving a first end and a second end longitudinally spaced from the firstend and forming a payload bay, the payload bay being sized to support apickface; a common active registration surface configured to engage thepickface; and a drive section connected to the common activeregistration surface, the drive section being configured to variablyposition the common active registration surface relative to at least onestorage shelf of an automated storage and retrieval system to effectplacement of the pickface on the storage shelf so that pickfaces aresubstantially continuously arranged along the at least one storage shelfwith a predetermined storage spacing between the pickfaces.

In accordance with one or more aspects of the disclosed embodiment thepredetermined storage spacing comprises only a sufficient clearancebetween adjacent pickfaces to allow contactless insertion or removal ofthe pickfaces to and from an allocated storage space.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover is configured to pick one or more items from one ormore storage location of the at least one storage shelf to build apickface.

In accordance with one or more aspects of the disclosed embodiment theat least one storage shelf comprises stacked storage shelves and theautonomous rover is configured to pick one or more items from one ormore storage location of the stacked storage shelves to build apickface.

In accordance with one or more aspects of the disclosed embodiment anautonomous rover is provided. The autonomous rover includes a framehaving a first end and a second end longitudinally spaced from the firstend and forming a payload bay, the payload bay being sized to support apickface; a common active registration surface configured to engage thepickface; and a drive section connected to the common activeregistration surface, the drive section being configured to variablyposition the common active registration surface relative to at least theframe.

In accordance with one or more aspects of the disclosed embodiment thevariable positioning of the common active registration surface effectsplacement of the pickface on a storage shelf so that pickfaces aresubstantially continuously arranged along the shelf with a predeterminedstorage spacing between the pickfaces.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover is configured to pick one or more items from one ormore storage locations of a storage shelf for building a pickface.

In accordance with one or more aspects of the disclosed embodiment theone or more storage location are disposed on storage shelves that arestacked one above the other.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover further includes a controller connected to the drivesection to effect movement of the common active registration surface sothat an average position of the common active registration surfacerelative to the payload bay is substantially coincident with apredetermined position of the pickface within the payload bay.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover of further includes a controller connected to the drivesection to effect movement of the common active registration surface forengagement with the pickface, the controller being configured to monitorat least a current value of the drive section to control an engagementforce of the common active registration surface with the pickface. Inanother aspect, the controller includes a Kalman filter configured todetermine the engagement force.

In accordance with one or more aspects of the disclosed embodiment thecommon active registration surface includes a first movable memberdisposed at least partly within the payload bay; and a second movablemember disposed at least partly within the payload bay, the secondmovable member being opposingly positioned relative to the first movablemember; wherein the drive section is configured to move the first andsecond movable members towards and away from each other and togetherlongitudinally as a unit.

In accordance with one or more aspects of the disclosed embodiment thedrive section is configured to variably position the common activeregistration surface relative to a global automated storage andretrieval reference frame.

In accordance with one or more aspects of the disclosed embodiment thevariable positioning of the common active registration surface decouplesplacement of the pickface from the frame.

In accordance with one or more aspects of the disclosed embodiment thepickface includes at least one case unit that is moved together as aunit.

In accordance with one or more aspects of the disclosed embodiment anautomated storage and retrieval system is provided. The automatedstorage and retrieval system includes an array of storage locations; andat least one autonomous rover in communication with the array of storagelocations, the at least one autonomous rover including a frame having afirst end and a second end longitudinally spaced from the first end andforming a payload bay, the payload bay being sized to support apickface; a common active registration surface configured to engage thepickface; and a drive section connected to the common activeregistration surface, the drive section being configured to variablyposition the common active registration surface relative to at least theframe.

In accordance with one or more aspects of the disclosed embodiment thevariable positioning of the common active registration surface effectsplacement of the pickface on a storage shelf of the array of storagelocations so that pickfaces are substantially continuously arrangedalong the shelf with a predetermined storage spacing between thepickfaces.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover is configured to pick one or more items from one ormore storage locations to build a pickface.

In accordance with one or more aspects of the disclosed embodiment theat least one autonomous rover further includes a controller connected tothe drive section to effect movement of the common active registrationsurface so that an average position of the common active registrationsurface relative to the payload bay is substantially coincident with apredetermined position of the pickface within the payload bay.

In accordance with one or more aspects of the disclosed embodiment theat least one autonomous rover further includes a controller connected tothe drive section to effect movement of the common active registrationsurface for engagement with the pickface, the controller beingconfigured to monitor at least a current value of the drive section tocontrol an engagement force of the common active registration surfacewith the pickface. In another aspect, the controller includes a Kalmanfilter configured to determine the engagement force.

In accordance with one or more aspects of the disclosed embodiment thecommon active registration surface includes a first movable memberdisposed at least partly within the payload bay; and a second movablemember disposed at least partly within the payload bay, the secondmovable member being opposingly positioned relative to the first movablemember; wherein the drive section is configured to move the first andsecond movable members towards and away from each other and togetherlongitudinally as a unit.

In accordance with one or more aspects of the disclosed embodiment thedrive section is configured to variably position the common activeregistration surface relative to a global automated storage andretrieval reference frame.

In accordance with one or more aspects of the disclosed embodiment thevariable positioning of the common active registration surface decouplesplacement of the pickface from the frame.

In accordance with one or more aspects of the disclosed embodiment thepickface includes at least one case unit that is moved together as aunit.

In accordance with one or more aspects of the disclosed embodiment anautonomous rover is provided. The autonomous rover includes a frameforming a payload bay, the payload bay being sized to support at leastone case unit; a first movable member disposed at least partly withinthe payload bay; a second movable member disposed at least partly withinthe payload bay, the second movable member being opposingly positionedrelative to the first movable member; a drive section connected to theframe and including a respective drive motor for each of first andsecond movable members, the drive section being configured to move thefirst and second movable members between a retracted and deployedpositions for engaging the at least one case unit; and a controllerconfigured to at least control the drive section for effecting movementof the first and second movable members; wherein the first and secondmovable members are configured to grip the at least one case unit andthe controller effects variably positioning the at least one case unitwithin the payload bay so that the positioning of the at least one caseunit is decoupled from the frame.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover further includes a controller configured to at leastcontrol the drive section for effecting movement of the first and secondmovable members towards and away from each other.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover further includes a controller configured to at leastcontrol the drive section for effecting movement of the first and secondmovable members as a unit along a length of the payload bay.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover further includes an end effector connected to the frameand being configured to transfer the at least one case unit to and fromthe payload bay; wherein the controller effects variably positioning theat least one case unit relative to the end effector. In other aspectsthe frame includes a first end; and a second end longitudinally spacedfrom the first end; wherein the end effector is configured for lateralmovement relative to the payload bay and the first and second movablemembers are arranged to longitudinally traverse a length of the payloadbay.

In accordance with one or more aspects of the disclosed embodiment eachrespective drive motor is mounted to a respective one of the first andsecond movable members and the drive section includes a common drivemember coupled to each of the respective drive motors, the common drivemember being movably fixed relative to the frame.

In accordance with one or more aspects of the disclosed embodiment eachrespective drive motor is mounted to the frame and the drive sectionincludes an independently movable drive member connected to each of therespective motors for coupling a respective one of the first and secondmovable members to the respective drive motor.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover further includes a linear guide member disposed belowthe payload surface, where the first and second movable members aremovably mounted to and depend from the linear guide member. In anotheraspect, each of the first and second movable members is cantileveredfrom the linear guide member.

In accordance with one or more aspects of the disclosed embodiment thedrive section comprises a two degree of freedom drive configured toindependently drive each of the first and second movable members.

In accordance with one or more aspects of the disclosed embodiment amethod for justifying at least one case unit within a payload bay of anautonomous rover is provided where the autonomous rover includes a frameforming the payload bay and an end effector for moving the at least onecase unit to and from the payload bay. The method includes providing afirst movable member and a second movable member at least partly withinthe payload bay; independently driving each of the first and secondmovable members for gripping the at least one case unit; and moving theat least one case unit with the first and second movable members forvariably positioning the at least one case unit within the payload bayso that the positioning of the at least one case unit is decoupled fromthe frame.

In accordance with one or more aspects of the disclosed embodiment theat least one case unit is positioned relative to the end effector.

In accordance with one or more aspects of the disclosed embodiment anautonomous rover for an automated storage and retrieval system isprovided. The autonomous rover includes a frame having a first end and asecond end longitudinally spaced from the first end, the frame forming apayload bay; a payload bed movably mounted at least partly within thepayload bay, the payload bed being movable in a first plane and having asubstantially frictionless payload support surface for allowingsubstantially snagless sliding of a pickface across the payload supportsurface; and a first gripping member and second gripping member movablymounted to the payload bed and being configured to laterally extendrelative to the frame and to grip only opposing sides of the pickface,at least one of the first and second gripping members beinglongitudinally movable relative to payload bed, where movement of thefirst and second gripping members is along a second plane substantiallyorthogonal to the first plane, and the first and second gripping membersmove as a unit with the payload bed in the first plane.

In accordance with one or more aspects of the disclosed embodiment thefirst and second gripping members are configured to electrostaticallygrip the opposing sides of the pickface.

In accordance with one or more aspects of the disclosed embodiment thefirst and second gripping members are configured to frictionally gripthe opposing sides of the pickface.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover further includes at least one sensor configured to atleast one of detect at least one boundary of the pickface gripped by thefirst and second gripping members, confirm empty storage spaces of apredetermined size exist on substantially flat storage shelvesaccessible to the autonomous rover, confirm the pickface is placed onthe substantially flat storage shelves with a predetermined setback,confirm a distance which the first and second gripper members areextended into a storage location of the substantially flat storageshelves, and provide guidance for placement of pickfaces in the storagelocations of the substantially flat storage shelves. In another aspect,the at least one sensor is disposed on at least one of the first andsecond gripping members.

In accordance with one or more aspects of the disclosed embodiment theframe includes a side fence, the payload bed being configured to moverelative to the frame to expose the side fence to a pickface disposed onthe substantially frictionless payload support surface.

In accordance with one or more aspects of the disclosed embodiment anautomated storage and retrieval system includes a storage structurehaving substantially flat storage shelves and at least one rover supportsurface disposed between adjacent substantially flat storage shelves,each storage shelf having a substantially snagless pickface supportsurface configured to allow sliding of a pickface across the snaglesspickface support surface; and an autonomous rover having a frameconfigured to traverse the at least one rover support surface, a payloadbed movably mounted to the frame, the payload bed having a substantiallyfrictionless payload support surface configured to allow sliding of apickface across the substantially frictionless payload support surface,and gripping members movably mounted to the payload bed, the grippingmembers being configured to grip only opposing sides of a pickface;wherein the gripping members are movable in at least two degrees offreedom relative to the frame for sliding transfer of the pickfacebetween the substantially frictionless payload support surface and thesubstantially snagless pickface support surface.

In accordance with one or more aspects of the disclosed embodiment thepayload bed moves in a first plane and the gripping members move in asecond plane that is orthogonal to the first plane.

In accordance with one or more aspects of the disclosed embodiment thegripping members comprise a longitudinally movable gripping member and astationary gripping member configured to positionally justify a pickfacerelative to the frame.

In accordance with one or more aspects of the disclosed embodiment thegripping members are configured to electrostatically grip the opposingsides of the pickface.

In accordance with one or more aspects of the disclosed embodiment thegripping members are configured to frictionally grip the opposing sidesof the pickface.

In accordance with one or more aspects of the disclosed embodiment thesubstantially flat storage shelves are configured to allow fluids topass through the substantially flat storage shelves. In another aspect,the substantially flat storage shelves have pass through stiffeningribs. In yet another aspect, the substantially flat storage shelvescomprise wire shelves. In still another aspect, fluid containment traysare positioned below at least one substantially flat storage shelf.

In accordance with one or more aspects of the disclosed embodiment theautonomous rover includes at least one sensor configured to at least oneof detect at least one boundary of the pickface gripped by the grippingmembers, confirm empty storage spaces of a predetermined size exist onthe substantially flat storage shelves, confirm the pickface is placedon the substantially flat storage shelves with a predetermined setback,confirm a distance which the gripper members are extended into a storagelocation of the substantially flat storage shelves, and provide guidancefor placement of pickfaces in the storage locations of the substantiallyflat storage shelves. In one aspect, the at least one sensor is disposedon at least one of the gripping members.

In accordance with one or more aspects of the disclosed embodiment theframe includes a side fence, the payload bed being configured to moverelative to the frame to expose the side fence to a pickface disposed onthe substantially frictionless payload support surface.

In accordance with one or more aspects of the disclosed embodiment thesubstantially flat storage shelves comprise a plurality of verticallyspaced storage shelves and the at least rover support surface comprisesa plurality of vertically spaced rover support surfaces where thepayload bed is movable relative to the frame for providing autonomousrover access to at least two of the vertically spaced storage shelvesfrom a single rover support surface.

It should be understood that the foregoing description is onlyillustrative of the aspects of the disclosed embodiment. Variousalternatives and modifications can be devised by those skilled in theart without departing from the aspects of the disclosed embodiment.Accordingly, the aspects of the disclosed embodiment are intended toembrace all such alternatives, modifications and variances that fallwithin the scope of the appended claims. Further, the mere fact thatdifferent features are recited in mutually different dependent orindependent claims does not indicate that a combination of thesefeatures cannot be advantageously used, such a combination remainingwithin the scope of the aspects of the invention.

What is claimed is:
 1. A method comprising: providing a frame having afirst end and a second end longitudinally spaced from the first end andforming a payload bay, the payload bay sized to support a pickface;providing at least a first common registration surface, a second commonregistration surface, and a third common registration surface, each ofthe at least the first common registration surface, the second commonregistration surface, and the third common registration surface engagingthe pickface supported on payload supports in the payload bay and beingdistinct and decoupled from the payload supports; providing a drivesection being connected to the at least the first common registrationsurface, the second common registration surface, and the third commonregistration surface; variably positioning, with the drive section, theat least the first common registration surface, the second commonregistration surface, and the third common registration surface relativeto each other and at least one storage shelf of an automated storage andretrieval system so as to justify the pickface in three degrees offreedom to effect placement of the pickface on the at least one storageshelf; and picking, with an autonomous rover, one or more items from oneor more storage locations of the at least one storage shelf to build thepickface.
 2. The method of claim 1, wherein variably positioning the atleast the at least the first common registration surface, the secondcommon registration surface, and the third common registration surfaceeffects placement of the pickface on a storage shelf so that pickfaces,the placement of each being so effected, are substantially continuouslyarranged along the shelf with a predetermined storage spacing betweenthe pickfaces.
 3. The method of claim 1, further comprising providing acontroller connected to the drive section and effecting movement, withthe controller, of one of the at least the first common registrationsurface, the second common registration surface, and the third commonregistration surface so that an average position of the one of the atleast the first common registration surface, the second commonregistration surface, and the third common registration surface relativeto the payload bay is substantially coincident with a predeterminedposition of the pickface within the payload bay.
 4. The method of claim1, further comprising providing a controller connected to the drivesection, effecting, with the controller, movement of one of the at leastthe first common registration surface, the second common registrationsurface, and the third common registration surface for engagement withthe pickface, and monitoring, with the controller, at least a currentvalue of the drive section to control an engagement for of the one ofthe at least the first common registration surface, the second commonregistration surface, and the third common registration surface with thepickface, wherein the controller determines the engagement force with aKalman filter.
 5. The method of claim 1, wherein one of the at least thefirst common registration surface, the second common registrationsurface, and the third common registration surface includes a firstmovable member disposed at least partly within the pay load bay, and asecond movable member disposed at least partly within the payload bay,the second movable member being opposingly positioned relative to thefirst movable member, the method further comprising moving, with thedrive section, the first and second movable members towards and awayfrom each other and together longitudinally as a unit.
 6. The method ofclaim 1, further comprising variably positioning, with the drivesection, the at least the first common registration surface, the secondcommon registration surface, and the third common registration surfacerelative to a global automated storage and retrieval system referenceframe.
 7. The method of claim 1, wherein variably positioning the atleast the first common registration surface, the second commonregistration surface, and the third common registration surfacedecouples placement of the pickface from the frame.
 8. An autonomousrover comprising: a frame having a first end and a second endlongitudinally spaced from the first end and forming a payload bay, thepayload bay being sized to support a pickface; at least a first commonregistration surface, a second common registration surface, and a thirdcommon registration surface, each of the at least the first commonregistration surface, the second common registration surface, and thethird common registration surface being configured to engage thepickface supported on payload supports in the payload bay, and distinctand decoupled from the payload supports; and a drive section beingconnected to the at least the first common registration surface, thesecond common registration surface, and the third common registrationsurface, wherein the autonomous rover is configured to pick one or moreitems from one or more storage locations of the at least one storageshelf to build the pickface, and the drive section is configured tovariably position the at least the first common registration surface,the second common registration surface, and the third commonregistration surface relative to each other and at least one storageshelf of an automated storage and retrieval system, so as to effectpicking of one item from the storage location with the autonomous roverholding another item, and to justify the one or more of the one itempicked and the other item held in three degrees of freedom, into acommon multi-item unit commonly defining the pickface in the payloadbay.
 9. The autonomous rover of claim 8, wherein the variablepositioning of the at least the first common registration surface, thesecond common registration surface, and the third common registrationsurface effects placement of the pickface on a storage shelf so thatpickfaces, the placement of each being so effected, are substantiallycontinuously arranged along the shelf with a predetermined storagespacing between the pickfaces.
 10. The autonomous rover of claim 8,further comprising a controller connected to the drive section to effectmovement of one of the at least the first common registration surface,the second common registration surface, and the third commonregistration surface so that an average position of the one of the atleast the first common registration surface, the second commonregistration surface, and the third common registration surface relativeto the payload bay is substantially coincident with a predeterminedposition of the pickface within the payload bay.
 11. The autonomousrover of claim 8, further comprising a controller connected to the drivesection to effect movement of one of the at least the first commonregistration surface, the second common registration surface, and thethird common registration surface for engagement with the pickface, thecontroller being configured to monitor at least a current value of thedrive section to control an engagement force of the one of the at leastthe first common registration surface, the second common registrationsurface, and the third common registration surface with the pickfacewherein, the controller includes a Kalman filter configured to determinethe engagement force.
 12. The autonomous rover of claim 8, wherein: oneof the at least the first common registration surface, the second commonregistration surface, and the third common registration surface includesa first movable member disposed at least partly within the payload bay,and a second movable member disposed at least partly within the payloadbay, the second movable member being opposingly positioned relative tothe first movable member; and wherein the drive section is configured tomove the first and second movable members towards and away from eachother and together longitudinally as a unit.
 13. The autonomous rover ofclaim 8, wherein the drive section is configured to variably positionthe at least the first common registration surface, the second commonregistration surface, and the third common registration surface relativeto a global automated storage and retrieval system reference frame. 14.The autonomous rover of claim 8, wherein the variable positioning of theat least the first common registration surface, the second commonregistration surface, and the third common registration surfacedecouples placement of the pickface from the frame.
 15. A methodcomprising: providing a frame having a first end and a second endlongitudinally spaced from the first end and forming a payload bay, thepayload bay sized to support a pickface; providing at least a firstcommon registration surface, a second common registration surface, and athird common registration surface, each of the at least the first commonregistration surface, the second common registration surface, and thethird common registration surface engaging the pickface supported onpayload supports in the payload bay and being distinct and decoupledfrom the payload supports; providing a drive section being connected tothe at least the first common registration surface, the second commonregistration surface, and the third common registration surface;picking, with the autonomous rover, one or more items from one or morestorage locations of the at least one storage shelf to build thepickface; and variably positioning, with the drive section, the at leastthe first common registration surface, the second common registrationsurface, and the third common registration surface relative to eachother and at least one storage shelf of an automated storage andretrieval system, so as to effect picking of one item from the storagelocation with the autonomous rover holding another item, and to justifythe one or more of the one item picked and the other item held in threedegrees of freedom, into a common multi-item unit commonly defining thepickface in the payload bay.
 16. The method of claim 15, whereinvariably positioning the at least the at least the first commonregistration surface, the second common registration surface, and thethird common registration surface effects placement of the pickface on astorage shelf so that pickfaces, the placement of each being soeffected, are substantially continuously arranged along the shelf with apredetermined storage spacing between the pickfaces.
 17. The method ofclaim 15, further comprising providing a controller connected to thedrive section and effecting movement, with the controller, of one of theat least the first common registration surface, the second commonregistration surface, and the third common registration surface so thatan average position of the one of the at least the first commonregistration surface, the second common registration surface, and thethird common registration surface relative to the payload bay issubstantially coincident with a predetermined position of the pickfacewithin the payload bay.
 18. The method of claim 15, further comprisingproviding a controller connected to the drive section, effecting, withthe controller, movement of one of the at least the first commonregistration surface, the second common registration surface, and thethird common registration surface for engagement with the pickface, andmonitoring, with the controller, at least a current value of the drivesection to control an engagement for of the one of the at least thefirst common registration surface, the second common registrationsurface, and the third common registration surface with the pickface,wherein the controller determines the engagement force with a Kalmanfilter.
 19. The method of claim 15, wherein one of the at least thefirst common registration surface, the second common registrationsurface, and the third common registration surface includes a firstmovable member disposed at least partly within the pay load bay, and asecond movable member disposed at least partly within the payload bay,the second movable member being opposingly positioned relative to thefirst movable member, the method further comprising moving, with thedrive section, the first and second movable members towards and awayfrom each other and together longitudinally as a unit.
 20. The method ofclaim 15, further comprising variably positioning, with the drivesection, the at least the first common registration surface, the secondcommon registration surface, and the third common registration surfacerelative to a global automated storage and retrieval system referenceframe.
 21. The method of claim 15, wherein variably positioning the atleast the first common registration surface, the second commonregistration surface, and the third common registration surfacedecouples placement of the pickface from the frame.